Radiator Support: Service and Repair

Inner Body Reinforcing Panels

General Equipment
3 Phase Inverter Spot Welder 254-00002
Compuspot 700F Welder 190-50080
I4 Inverter Spot Welder 254-00014
Inverter Welder with MIG Welder 254-00015







Front Structure

NOTE: LH fender apron and frame rail view shown, RH similar.







WARNING: Collision damage repair must conform to the instructions contained. Replacement components must be new, genuine Ford Motor Company parts. Recycled, salvaged, aftermarket or reconditioned parts (including body parts, wheels or safety restraint components) are not authorized by Ford.
Departure from the instructions provided, including alternate repair methods or the use of substitute components, risks compromising crash safety. Failure to follow these instructions may adversely affect structural integrity and crash safety performance, which could result in serious personal injury to vehicle occupants in a crash.

NOTE:
- Factory spot welds may be substituted with either resistance spot welds or Metal Inert Gas (MIG) plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.
- The following steps provide a general guideline for replacement of body structure components. Refer to exploded views for specific component and assembly information.

1. NOTICE: Electronic modules and related wiring may be damaged when exposed to heat from welding procedures. Carefully disconnect and remove, or position away from heat affected areas.

NOTE: When it is necessary to carry out weld-bonding procedures, refer to Weld-Bonding.

Remove the outer body sheet metal from the affected area prior to carrying out any reinforcing panel replacement.

2. Where possible, create a backer piece using a portion of the old panel. This will create a stronger joint.
3. When welding overlapping surfaces or substrates, apply a weld-through primer between the surfaces prior to welding. When the surfaces have been welded, apply corrosion protection material to the exterior surfaces or substrates.
- Make sure horizontal joints and flanges are correctly sealed with seam sealer to prevent moisture intrusion. Water and moisture migrate to horizontal joints and corrosion tends to occur more rapidly in these areas. Metal surfaces must be clean and dry before applying seam sealer.

4. Proceed with refinishing procedures following Ford-approved paint guidelines. Apply corrosion protection to the repair area as required.